Basic Manufacturing,

✍ Scribed by Roger Timings

• Publisher: Newnes
• Year: 2004
• Tongue: English
• Leaves: 313
• Edition: 3
• Category: Library

✦ Synopsis

Basic Manufacturing has already established itself as a core text for manufacturing courses in Further Education. The new edition has been revised to be fully in line with the new Vocational GCSE in Manufacturing from Edexcel, covering the three compulsory units of this scheme, and will continue to act as a core text for Intermediate GNVQ. Coverage of the two schemes is combined throughout the text, yet each chapter clearly illustrates which sections map to which units within the two scheme specifications. The author's approach is student-centred with self-check questions and activities provided throughout. As a result, the book is well suited to independent study. It is also clearly written to appeal to students of all abilities. Review questions are provided at the end of each chapter to consolidate learning and give practice for external assessments. The third edition contains a brand new chapter to cater for the examinable part of the GCSE syllabus (Unit 3), which includes case studies in the six sectors covered in the scheme: food and drink/biological and chemical; printing and publishing/paper and board; textiles and clothing; engineering fabrication; mechanical/automotive engineering; electrical and electronic engineering/computer/process control/telecommunications. The book is an excellent, readable introduction to the technical and business aspects of the manufacturing industry that will be invaluable for students on a wide range of courses, including City and Guilds certificates. It also provides a good grounding for students embarking on higher-level programmes within Manufacturing. Roger Timings is one of the UK's leading authors of textbooks on manufacturing and engineering. * Unit by unit match to the new Vocational GCSE in Manufacturing from Edexcel * Core text also meets the requirements of Intermediate GNVQ Manufacturing * Student-friendly approach, with numerous examples, case studies, and problems included throughout

✦ Table of Contents

Cover......Page 1
Basic manufacturing......Page 4
Contents......Page 6
Preface......Page 8
Acknowledgements......Page 9
1.1 What is manufacturing......Page 10
1.2 The main UK manufacturing sectors......Page 12
1.3 The chemical industry......Page 13
1.4 The engineering industry......Page 16
1.4.1 Electrical and electronic engineering......Page 17
1.4.3 Mechanical engineering......Page 19
1.4.4 Transportation equipment manufacturing......Page 20
Bakery products......Page 25
Processed foods (cereals, fruit and vegetables)......Page 26
Soft drinks......Page 27
Brewing......Page 28
Spirit distilling......Page 29
1.6 Paper and board manufacture......Page 30
1.6.1 Printing and publishing......Page 31
1.7 Textiles, clothing and footwear......Page 32
Synthetic fibres......Page 33
1.7.2 The clothing industry......Page 34
1.8 The importance of the main manufacturing sectors to the UK economy......Page 35
1.8.3 Balance of trade......Page 36
1.9.3 Incentives......Page 38
1.9.5 Transport and markets......Page 39
1.10 Key stages of production (example)......Page 40
1.10.1 Sourcing and procurement......Page 41
1.11 Key stages of production (general)......Page 42
1.12 Scales of production......Page 45
1.12.2 Batch production......Page 46
1.12.3 Small batch, prototype and jobbing production......Page 49
1.12.4 Production systems......Page 51
Assessment activities......Page 52
2.1.2 Development of a design brief: the client......Page 53
2.1.3 Identifying client need......Page 54
2.1.5 The design process......Page 55
Aesthetics......Page 58
Performance......Page 59
Quality standards......Page 60
Available plant......Page 61
2.2 Materials used in manufacture......Page 62
2.2.1 Availability and forms of supply (metals)......Page 63
Natural rubber......Page 67
Synthetic rubbers (elastomers)......Page 68
Plastics......Page 70
Plywood......Page 72
Cermets......Page 73
Man-made (synthetic) fibres......Page 74
Yarns......Page 75
2.2.5 Woven fabrics......Page 76
Plain weave......Page 77
Twill weave......Page 78
Weft knitted fabrics......Page 79
Bonded webs......Page 80
Mixtures, compounds and blends......Page 81
Strength......Page 82
Rigidity (stiffness)......Page 83
Plasticity......Page 84
Malleability......Page 85
Hardness......Page 86
Hard magnetic materials......Page 87
2.4.5 Flow rate......Page 88
2.4.8 Texture......Page 89
Weathering......Page 90
2.5.2 Available materials......Page 92
2.5.4 Health and safety requirements......Page 93
2.6 Quality standards......Page 94
2.6.2 Quality control......Page 95
2.6.4 Points of inspection......Page 96
2.6.6 Statistical sampling techniques......Page 99
Critical defects......Page 101
Quality of materials......Page 102
Tolerance......Page 103
Health, safety and hygiene......Page 104
2.7 Generating proposals to meet a design brief......Page 105
2.7.1 Assessing the feasibility of design proposals......Page 108
2.7.2 Selecting preferred designs......Page 110
Overhead projector......Page 111
Computerized presentation......Page 112
Qualitative judgements......Page 113
Reports......Page 114
Visual aids......Page 115
Visual aids (video recordings)......Page 116
2.8.1 Graphs......Page 117
2.8.3 Bar charts......Page 118
2.8.4 Gantt chart......Page 119
2.8.5 Pictograms (ideographs)......Page 120
2.8.7 Flow charts......Page 121
2.8.8 System flow charts......Page 122
2.9 Technical drawings......Page 123
2.9.3 General arrangement drawing (GA)......Page 124
2.9.5 Exploded drawing......Page 125
2.9.7 Using computer-aided design (CAD)......Page 126
2.10 Patterns, samples and swatches......Page 129
2.11 From design brief to finished product......Page 133
2.11.2 Design proposal......Page 134
2.11.5 Finished product......Page 135
2.12.1 Direct costs (materials)......Page 136
2.12.4 Indirect costs......Page 137
Research and development costs......Page 138
Method 1......Page 139
Method 2......Page 140
Assessment activities......Page 142
3.1.1 Introduction......Page 143
3.1.2 Product specification......Page 144
Critical control points......Page 145
3.1.3 Key production stages......Page 146
Capital resources......Page 147
Tooling resources......Page 148
Indirect labour......Page 149
3.1.5 Processing times......Page 150
3.1.6 Production schedules......Page 152
3.1.7 Producing a production plan......Page 155
3.3 The preparation of materials and components......Page 158
3.4.1 Manual (non-automated) machinery......Page 159
3.4.2 Automated machinery......Page 160
Lighting......Page 163
3.5 The preparation of tools and equipment......Page 164
Scissors......Page 165
Files......Page 166
Drills......Page 168
Spanners......Page 171
Soldering irons......Page 173
Needles......Page 176
3.6.1 Control and adjustment of manual equipment and machinery......Page 177
3.6.2 Automated equipment and machinery......Page 179
Hardening......Page 183
Ultra-heat treatment (UHT)......Page 184
Injection moulding......Page 185
Extrusion moulding......Page 186
Blow moulding......Page 187
Casting......Page 188
Sheet metal pressing......Page 190
3.7.2 Toxicity......Page 193
3.7.3 Oxidation......Page 194
3.7.6 Contamination......Page 195
3.7.9 Discolouration......Page 196
3.8.1 Semi-permanent fastenings......Page 197
3.8.2 Permanent fastenings (mechanical)......Page 198
Compression joints......Page 199
3.8.3 Permanent fastenings (thermal)......Page 202
Electric arc welding......Page 203
Soldering (hard)......Page 204
Resistance (spot and seam) welding......Page 206
Ultrasonic welding......Page 207
Adhesive (chemical) jointing......Page 209
Elastomeric adhesives......Page 210
3.9 Assembly of components and subassemblies to specification and quality standards......Page 211
3.9.1 Finishing methods......Page 212
Applied liquid finishes (organic)......Page 213
Hot dip galvanizing......Page 214
Conversion coatings......Page 215
Buffing (polishing)......Page 216
Colouration......Page 217
3.10.1 Quality indicators......Page 218
Operator errors......Page 219
Process condition changes......Page 220
Material substitution......Page 221
Investigate cause......Page 222
Scrap......Page 223
3.11 Safety equipment, health and safety procedures and systems......Page 224
3.11.2 Emergency equipment (fire)......Page 225
3.11.4 Personal safety clothing and equipment......Page 227
Safety footwear......Page 229
Ear defenders......Page 230
Hats and caps......Page 231
Physically dangerous environments......Page 232
3.11.6 Safety equipment and systems......Page 233
Guards......Page 234
Safety valves......Page 235
Emergency stop buttons......Page 236
3.12.1 Maintenance procedures......Page 237
3.12.7 Cutting tools......Page 238
3.12.8 Assembly tools......Page 239
Assessment activities......Page 240
4.1 The use of information and communication technology......Page 241
Intranets......Page 242
Case study 4.1: The Internet and the World Wide Web......Page 243
Case study 4.2: Databases......Page 245
Case study 4.3: Spreadsheets......Page 247
Case study 4.4: Computer-aided engineering......Page 249
4.1.5 Rapid prototyping......Page 253
Case study 4.5: Rapid prototyping......Page 254
4.1.6 Reverse engineering......Page 255
4.1.7. Computer numerical control (CNC)......Page 256
Axis nomenclature......Page 257
Control systems......Page 258
Management words......Page 259
Canned cycles......Page 261
Case study 4.7: A simple milling program......Page 262
Case study 4.8: A simple turning program......Page 263
4.2.1 Automation and control......Page 265
Case study 4.9: Programmable logic controllers......Page 266
4.2.2 Industrial robots......Page 268
Off-line’ programming......Page 269
Cylindrical co-ordinate robots......Page 270
Revolute co-ordinate robots......Page 271
The wrist......Page 272
Case study 4.10: Pick and place robot......Page 273
Level 1......Page 275
4.3.1 Shape memory materials......Page 276
Case study 4.12: Coated and smart fabrics......Page 278
Case study 4.13: Specialized adhesives......Page 279
4.3.4 Biodegradable plastics......Page 281
4.3.6 Computer technology......Page 282
Case study 4.14: The microprocessor......Page 283
Case study 4.15: Microprocessor systems......Page 284
4.3.2 Plastic coatings and adhesives......Page 277
4.4.1 Range, types and availability of products......Page 287
4.4.3 Improved characteristics of manufactured products......Page 288
4.5.1 Changes in the type and size of the workforce......Page 289
4.5.2 Changes in the working environment......Page 290
Pollution......Page 291
Sustainability......Page 292
4.6 The stages in manufacturing a product......Page 293
4.6.1 Materials requirement planning (MRP 1)......Page 296
Bill of materials......Page 297
4.6.2 MRP 1 in action......Page 298
4.6.3 Manufacturing resource planning (MRP 2)......Page 299
Master production statement (mission statement)......Page 300
Case study 4.17: Investigating a compact disc (CD)......Page 301
Assessment activities......Page 304
C......Page 306
E......Page 307
I......Page 308
M......Page 309
P......Page 310
S......Page 311
V......Page 312
Y......Page 313